Process for manufacturing tape products

ABSTRACT

A process for the manufacture of a plastisol film or foam tape laminate comprises providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; casting a liquid plastisol formulation onto the adhesive; fusing, and in the case of a foam tape, expanding the plastisol formulation to form a thermoplastic layer on the adhesive; and, winding the resulting tape laminate onto rolls. Also, a process for the manufacture of a plastisol film or foam tape laminate comprises providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a liquid plastisol formulation onto the barrier film; fusing, and in the case of a foam tape, expanding the plastisol formulation to form a thermoplastic layer on the barrier film; and, winding the resulting tape laminate onto rolls.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. Ser. No. 09/094,767, filed Jun. 15, 1998 now U.S. Pat. No. 5,951,507, which claims priority from U.S. Provisional Patent Application Ser. No. 60/048,926, filed Jun. 16, 1997.

TECHNICAL FIELD

The present invention is directed to a process for manufacturing tape products. More particularly, it is directed to a process for manufacturing an adhesive tape comprising a plastisol film or foam and an adhesive, on a release liner.

BACKGROUND OF THE INVENTION

It has been the practice in the art to cast a plastisol film or foam suitable for use as a tape product, such as a bandage or wound dressing, on a casting sheet in a first stage on one apparatus, and then deliver the laminate to a second apparatus in roll form. The casting sheet is conventionally a siliconized paper about 60 inches wide, and several thousand yards long, impregnated with clay or some other saturant, to provide a smooth surface for the cast.

On the second apparatus, the roll of the film or foam/casting sheet laminate is mounted for contacting with a liner (such as a kraft paper on the order of about 60 pounds), which liner is first coated on one side with a release layer, such as a silicone compound, and then coated with an adhesive on top of the silicone. The film or foam is then laminated in the second stage to the adhesive layer, such that the film or foam is interposed between its casting sheet, or carrier, on one side, and the adhesive layer of the new adhesive coated liner on the other side. The casting sheet, or carrier, is then stripped off of the laminate, and is discarded.

If the tape product is to be used as a bandage or wound dressing, the rolled sheet is perforated (such as being rolled with pins) and then is cut to size, in one application on the order of 31/4 inches wide, although the width could vary. The length of the bandage, is thereafter cut from the width of the roll, in a third stage. The narrow laminate is conventionally wound in large rolls, for delivery to a third apparatus.

In a third stage, the heavy liner is stripped off the narrow laminate. The adhesive sticks to the film or foam, but not the liner. In the case of a bandage, an adsorbant pad is applied to the adhesive, and a new about 40 to about 50 pound liner, comprising two overlapping pieces that form the "pull tab", is laminated. The new laminate is then passed to a cutter, or a die.

In one embodiment, the plastisol foam comprises foamed polyvinyl chloride, or PVC foam. PVC foam is conventionally cast at the relatively high temperature of about 300° to about 400° F., requiring a dense casting surface with easy release. Otherwise, the resulting PVC foam will not form a flat, glossy sheet as desired, as water vapor or bubbles adsorbed on the casting sheet will be taken up in the foam. Also, if a dense casting sheet is not utilized, an easy release will not be effected in the stripping process in the third stage.

In the conventional process, a rate limiting step is stripping off the heavy casting sheet during the second stage, at the point that the film or foam is laminated to the adhesive coated release liner. Further, the heavy, treated casting sheet is normally discarded. It is therefore desirable to bypass the rate limiting procedure. It is further desirable to economize by avoiding the use of the heavy, extra casting sheet, such that the cost of both its purchase in the first instance, and its disposal after use, are avoided.

A further disadvantage to the conventional process is that it is necessary, during the second stage, to splice both the liner and the film or foam, when each reaches the end of the rolls on the apparatus. The spliced section passes through to the third stage and into the finished product. These spliced products must be culled out of the product before packaging and/or delivery to the customer. This culling process causes additional wastage and the slowing of run speeds, resulting in inefficiencies in the process.

Another disadvantage in the conventional process, that is, utilizing a preformed film or foam on a casting sheet, is the requirement that the adhesion of the film or foam to the adhesive coated release liner be more tenacious than the adhesion to the casting sheet, so that the casting sheet can be stripped off without delaminating the film or foam from the liner. This balance is difficult to achieve. Also, too high an adhesion to the liner will make conversion of the tape laminate to, for example, a bandage type product more difficult, as the release liner must then be stripped from the tape.

Tape products currently used in the industry which are affixed to electrodes for the purposes of medical diagnosis or drug delivery have several distinct limitations. Changes to the tape product construction, such as swelling or shrinkage of the various component layers, often results in the modification of the electrode signal and exposing the patient to a risk of electrical shock from the electrode. Furthermore, many tape products for electrodes experience a loss of adhesive integrity due to the changes in the component layers. Therefore, it is desirable to develop a tape construction useful for fabrication of medical electrodes to be adhered to human skin, which overcome the limitations and disadvantages of the tape products of the prior art.

SUMMARY OF THE INVENTION

It is an object of the present invention to avoid the use and cost of a heavy casting sheet that is discarded prior to sizing the width of the tape product.

It is a further object of the present invention to provide a continuous plastisol film or foam tape and a process for producing it, that does not contain sections of spliced film or foam material.

It is a further object of the present invention to provide a continuous plastisol film or foam tape, a plastisol film or foam tape laminate, and a process for producing it that inhibits plasticizer migration from the plastisol formulation.

It is a further object of the present invention to provide a process for casting a plastisol film or foam tape laminate that avoids exposing the adhesive to the casting apparatus.

The present invention therefore provides a process for the manufacture of a tape comprising providing a continuous liner having a release layer; depositing an adhesive onto the release layer; casting a liquid plastisol formulation onto the adhesive; and, fusing the plastisol formulation to form a thermoplastic layer on the adhesive.

In one embodiment, the present invention provides a process for the manufacture of a plastisol foam tape comprising providing a continuous liner having a release layer; depositing an adhesive onto the release layer; drying the adhesive; casting a foamable liquid plastisol formulation onto the adhesive; and, fusing and expanding the foamable plastisol formulation to form a plastisol foam on the adhesive.

In one embodiment, the present invention further includes cutting the tape substantially parallel to its long axis to a selected width, and winding the tape onto rolls.

The present invention further provides a one stage process for the manufacture of a tape laminate comprising providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; casting a liquid plastisol formulation onto the adhesive; fusing the plastisol formulation to form a thermoplastic layer on the adhesive; and, winding the resulting tape laminate onto rolls. The present invention further provides the tape product of the process.

The present invention further provides a one stage process for the manufacture of a plastisol foam tape laminate comprising providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; casting a foamable liquid plastisol formulation onto the adhesive; fusing and expanding the foamable plastisol formulation to form a plastisol foam on the adhesive; and, winding the foam tape laminate onto rolls. The present invention further provides the foam tape product of the process.

In another embodiment, the present invention provides a process for the manufacture of a plastisol foam tape comprising providing a continuous liner having a release layer; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a foamable liquid plastisol formulation onto the barrier film; and, fusing and expanding the foamable plastisol formulation to form a plastisol foam on the barrier film.

The present invention further provides a one stage process for the manufacture of a plastisol foam tape laminate comprising providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a foamable liquid plastisol formulation onto the barrier film; fusing and expanding the foamable plastisol formulation to form a plastisol foam on the barrier film; and, winding the foam tape laminate onto rolls. The present invention further provides the foam tape product of the process.

The present invention further provides a process for the manufacture of a tape comprising providing a continuous liner having a release layer; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a liquid plastisol formulation onto the barrier film; fusing the plastisol formulation to form a thermoplastic film layer on the barrier film.

The present invention further provides a one stage process for the manufacture of a tape laminate comprising providing a continuous liner; forming a release layer along the length of one side of the liner; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a liquid plastisol formulation onto the barrier film; fusing the plastisol formulation to form a thermoplastic layer on the barrier film; and, winding the resulting tape laminate onto rolls. The present invention further provides the tape product of the process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a three roll reverse coating system.

FIG. 2 is a schematic representation of a knife over roll coating system.

FIG. 3 is a schematic representation of a slot coating system.

FIG. 4 is a cross sectional view of a foam tape laminate produced according to the process of the present invention.

FIG. 5 is a cross sectional view of one embodiment of the present invention, namely a foam tape laminate having a barrier film disposed between the adhesive layer and the plastisol foam layer produced according to the process of the present invention.

PREFERRED EMBODIMENTS OF THE INVENTION

The present invention is directed to a process for manufacturing a continuous plastisol film or foam adhesive tape laminate in a single operation. The present invention avoids having to cast the film or foam in an operation separate from the formation of the laminate of the film or foam with the adhesive coated release liner.

Optimally, the entire laminate is prepared in one continuous operation, including the formation of the release layer on the liner, the deposition and drying of the adhesive, and the casting (depositing), and if applicable, the foaming of the plastisol formulation on the adhesive layer. It is within the scope of the invention, however, to separately form the liner/release/adhesive laminate, and thereafter cast the plastisol formulation onto exposed adhesive, optionally in a separate stage, as the advantages of the present invention derive in part from avoiding the use of a heavy, discardable casting sheet for the film or foam. The invention includes the discovery that a high quality film or foam can be cast, fused and (in the case of a foam) heat expanded directly on an adhesive without damage to the adhesive's properties, or the fusing of the adhesive with the underlying release layer.

In one embodiment of the invention, a heavy weight, clay coated kraft paper, on the order of about 62 pounds to about 78 pounds, is provided as a continuous liner. A release layer is formed by applying a conventional silicone release compound onto the liner and curing. An adhesive is deposited onto the silicone release layer, such as by casting a liquid solution of the adhesive and then drying.

A liquid, foamable plastisol formulation is then cast (deposited) onto the dried adhesive, and subjected to heat sufficient to fuse and then expand the plastisol formulation into a foam. For a PVC plastisol, the temperature range for expanding the foam is generally on the order of about 300° to about 400° F.

Surprisingly, we have demonstrated that it is possible to cast a foamable plastisol onto an adhesive surface, and still get a good quality foam, comparable to or improved over plastisol foams prepared by casting onto a conventional casting sheet. Further, it was unpredictable that the adhesive would still have adhesive properties once it had the plastisol formulation (which includes a plasticizer) applied to it and went through an oven at the high foam expanding temperatures required to fuse and expand PVC plastisols into foam. The adhesive, rather than fusing to the silicone compound upon exposure to the high temperature as was expected, releases from the silicone when pulled, but retains sufficient adhering properties for use in the tape product.

Further, we have found that when the plastisol is cast and fused in place on top of the adhesive, the bond between the adhesive and the resulting thermoplastic layer is greater than when the adhesive is laminated to the thermoplastic. One test for adhesive tenacity to the film or foam is to contact the adhesive on the film or foam to itself and pull the adhered sections apart, to determine whether any adhesive comes off. Adhesive pickoff is a critical test for bandages, as it is undesirable for the adhesive to come off of the bandage onto the skin of the user.

For the liner paper, a dense surface is needed. Even though a silicone and an adhesive is layered on the paper, if there is porosity in the paper, the film or foam that is cast onto it will have defects, such as pinholes, voids, and bubbles, resulting from moisture coming out of the paper at high temperature and evaporating, and/or geometric variations in the surface of the paper. A suitable weight paper is about 40 pounds to about 100 pounds, preferably about 62 pounds to about 78 pounds. A light weight release liner will tend to curl from the wet plastisol. Heavier weight liners approximate the casting paper which is avoided by the present invention. The liner papers used according to the present invention need not be stripped and replaced prior to perforation of the film or foam and conversion of the sized product roll to the thin, overlapping "pull-tab" lined product (such as for a bandage).

The surface of the paper is preferably clay coated, or coated with another conventional saturant. Suitable papers include, but are not limited to, 58, 63 and 78 pound clay coated, supercalendered kraft paper, available from Boise Cascade Corporation (Portland, Oreg.). Other suitable liners include pre-siliconized release coated Multithane or UltraMatte liners from Arjo Wiggins, and lacquered liners from Boise Cascade or Avery Dennison Release Coated Materials Division (Mentor, Ohio).

Suitable release compositions for use in the present invention include conventional silicone release compounds, including platinum or rhodium catalyst cured silicone and radiation cured release coatings. As stated above, the release layer can be applied in the same operation as the casting of the plastisol layer, or can alternatively be precoated on the liner. The silicone release compound is preferably an easy release system, for use in tape products. Suitable silicone release compositions include, but are not limited to vinyl-substituted polydimethylsiloxane resins such as GE SS4331 or GE 5000 from GE Plastics, and Syl-Off resin systems from Dow.

The adhesive useful in the present invention is a pressure sensitive adhesive, releasable from the underlying release composition. The adhesive should not be adversely affected by the plastisol formulation. Suitable adhesives include those that are acrylic based adhesives, preferably, those that are not tackified, and most preferably having high cross-linker levels.

The adhesive is preferably applied to the release layer as a solution of the acrylic composition. In one embodiment, the acrylic adhesive is applied in a toluene and/or heptane solvent or emulsion, and the solvent or carrier liquid is dried off by heating, at about 120° to about 240° F., preferably about 140° to about 180° F. In another embodiment, a vinyl pyrrolidone polymer in a hexane/toluene solvent is utilized, having a crosslinker. The thickness of the dried adhesive layer varies with the application for which it is intended. For skin bandages, the adhesive layer is generally on the order of about 1.5 to about 2.5 mils thick.

When the tape product is a bandage, the adhesive composition is a biocompatible pressure sensitive adhesive. Preferably it is a polyvinyl ester-based acrylic adhesive. The adhesive may have relatively low aggressiveness, but should have sufficient adhesion to skin when used with the film or foam of the present invention. The adhesive may be the same as those in conventional bandages, at coating weights from about 10 g/m² to about 250 g/m², preferably from about 25 g/m² to about 75 g/m².

The coating conditions for both the release layer and the adhesive are conventional in the industry. As is the case with the release layer, the adhesive layer can be applied in the same operation as the casting of the plastisol layer, or can alternatively by precoated on the release liner. The adhesive can be applied in a uniform coat, or in a pattern appropriate for the end product.

It should be noted that the adhesive is dried at high temperature in proximity to the silicone release compound. Further, the silicone release compound and the adhesive are "heat aged" in contact with each other while making the tape product, as the plastisol formulation is expanded to produce the foam in one embodiment, at about 300° to about 400° F. If the adhesive and the release compound do not have a very easy release characteristic with respect to each other, the two compositions will weld, and will not be able to be separated when the laminate is stripped to replace the intermediate weight casting liner with the light weight paper liner of the final product.

In a test to determine release properties, the silicone release composition is applied to the liner paper and is cured. A sheet having the adhesive on it is then laminated to the silicone. After subjecting the laminate to the heat aging conditions, the force it takes to peel them apart is measured on an Instron tester.

A steel plate (Keil plate) is placed on the laminate at 0.25 psi pressure and placed in an oven at 158° F. for 20 hours. The laminate is then pulled apart at 300 inches per minute at a 90° peel angle.

The release force should not be too low, and should preferably be greater than 50 grams/2 inches because during the production process, the laminate normally passes over and under rollers. The aggressive adhesive side contacts rollers, but must stay on the silicone release compound and not transfer onto the roller. An unacceptable force is greater than 500 grams/2 inches of sample width, since it is undesirable for subsequent processing, due to the tendency of the film, foam or paper to tear at high release forces. According to the present invention, a peel force of 200-225 grams/2 inches is achieved, as compared to a control formulation providing 350-400 grams/2 inch tape peel force. A peel force up to about 400 grams/2 inches is acceptable, but it is preferably lower.

The plastisol formulation which is cast onto the adhesive layer of the adhesive/release/liner laminate comprises a resin, a plasticizer, and in the case of the foam a blowing agent, and optionally an activator/stabilizer, a viscosity depressant, pigment, filler and defoamer. The plastisol preferably contains a PVC resin.

The plastisol formulation preferably contains about 100 to about 120 parts by weight plasticizer per 100 parts resin when a foamable resin formulation is desired, together with about 0.5 to about 2 parts blowing agent. A foamable plastisol resin dispersion may comprise a foamable PVC resin, and optionally up to about 40% of the total resin of a blending resin. When a film, rather than a foam is to be manufactured, the plastisol formulation preferably contains about 30 to about 100 parts by weight plasticizer per 100 parts resin, and the blowing agent is omitted.

The plastisol formulation is applied to the adhesive layer of the adhesive/release/liner laminate in a solventless, solution or slurry/dispersion form. Techniques conventional in the industry for applying plastisol formulations to a substrate can be used, such as roll coating, knife over roll coating, and extrusion or slot coating.

A representation of three roll reverse coating 10 is shown in FIG. 1, in which a fountain roll 11 carries the plastisol formulation 12 solution or dispersion from a reservoir 13 to an application roll 14, which then accurately applies the plastisol formulation 12 onto the adhesive layer of the laminate 15, being carried by the backing roll 16. The thickness of the liquid plastisol coating is controlled by the speed of the application roll 14 as well as the gap between the fountain roll 11 and application roll 14 and the gap between the application roll 14 and backing roll 16, considering the thickness of the laminate 15 onto which the plastisol is being applied. This coating method is versatile and accurate, and handles a wide range of viscosities of the plastisol formulation. It can accommodate uneven web surfaces, to yield a uniform plastisol film thickness.

An alternative application technique is the knife over roll method 20, represented in FIG. 2. In this high shear method, the plastisol formulation liquid 21 is extruded from a passage formed by a rigid and stationary knife 22, under which is passing the adhesive/release/liner laminate 23 supported by a hard backup roll 24. This technique accommodates a variety of feed systems conventional in the art, such as roller feed, hopper feed, and die feed. This method also accommodates a wide viscosity range of the plastisol formulation 21, and is simple to operate. The coating thickness of the plastisol coating is effected by the gap between the knife 22 and the laminate 23 carried on the backup roll 24 (the coating being about 1/2 the thickness of the gap), by blade thickness, viscosity (increasing lowers weight of plastisol applied), web speed (increasing lowers weight of plastisol applied), and plastisol fluid surface tension (increasing the surface tension increases the weight applied).

A third method for applying the plastisol to the adhesive/release/liner laminate is by slot coating 30, represented in FIG. 3. This technique is very accurate, but is most difficult to control. The plastisol formulation fluid 31 is extruded through a slot 32 in a die body 33, into a coating gap 34 between the die outlet 35 and the laminate 36, being carried on a backing roll 37. Thickness of the coating is controlled by the thickness of the gap, flow rate, density and temperature of the fluid, the rheology curve (shear/viscosity) and the thixotropy of the fluid (viscosity decreasing with increased shear). Other variables include the diameter of the backing roll 37, the backing roll hardness, and the web 36 line speed.

The thickness of the plastisol formulation which is applied depends upon the application for which it is intended. For skin bandages, generally a thickness of about 3 to about 20 mils is desired. In one embodiment, it is preferred that the thickness of the liquid plastisol coating be about 10 mils.

The plastisol liquid is then subjected to heat, sufficient to fuse the resin, and in the case of a foam, to expand the foam, by activation of the blowing agent in the formulation. The blowing agent may be activated either during or after extrusion of the plastisol onto the laminate. Activation is by means conventional in the art, such as by heating in an oven.

Expansion of the foam generally results in the thickness of the plastisol foam being about twice the thickness of the applied liquid coating. For example, the expansion of a 10 mil liquid plastisol coating can result in a foam of about 20 to about 22 mils thick. The amount of expansion is controlled by variables such as dwell time, temperature, and the amount and type of blowing agent.

A representation of a foam tape 40 produced according to the present invention is shown in FIG. 4. The liner backing 41 carries the release layer 42, onto which is disposed the adhesive 43, over which is coated the foam 44. If the foam 44 is to be used as a skin bandage, it is rendered more permeable to air by perforation, such as by passing the foam carrying laminate in contact with a roller carrying pins for perforating the foam.

In another embodiment, the present invention provides a process for the manufacture of a plastisol foam tape comprising providing a continuous liner having a release layer. An adhesive is deposited onto the release layer and dried, as discussed hereinabove. After drying of the adhesive layer, a barrier film, such as a thin vinyl film is disposed onto the dried adhesive. Finally, a foamable liquid plastisol formulation is cast onto the barrier film; and, is fused and expanded to form a plastisol foam on the barrier film layer. The construction of this embodiment avoids exposing the casting machine to the adhesive layer. Furthermore, placing a barrier film between the adhesive layer and the plastisol foam layer prevents the migration of the plasticizer from the plastisol foam into the adhesive. This embodiment of the present invention is useful for preparing self-adhesive tape products, such as for adhering to an electromedical device used in a diagnostic procedures and iontophoresis (drug delivery) to mammalian skin.

The entire construction may be prepared in one continuous operation, including the formation of the release layer on the liner, the deposition and drying of the adhesive, depositing or casting of the barrier film onto the adhesive layer, the deposition of the plastisol formulation, and, if applicable, the foaming of the plastisol formulation on the barrier film. It is within the scope of the invention, however, to separately form the liner-release adhesive-barrier film laminate, and thereafter cast the plastisol formulation onto the barrier film, optionally in a separate stage, as the advantages of the present invention derive in part from avoiding the use of a heavy, discardable casting sheet for the film or foam. This embodiment of the invention includes the discovery that a high quality film or foam can be cast, fused and (in the case of a foam) heat expanded directly on a barrier film layer, thus avoiding contact between the plastisol foam and the adhesive layer, and avoiding damaging the adhesive's properties or the fusing of the adhesive with the underlying release layer, as well as preventing the migration of the plasticizer from the plastisol foam into the adhesive during processing, storage and/or use.

In another embodiment, after the adhesive layer has dried, a barrier film is laminated onto the dried adhesive layer. The barrier film contains a barrier coating to prevent the migration of the plasticizer into the adhesive layer.

A liquid, foamable plastisol formulation is then cast (deposited) onto the barrier film, and subjected to heat sufficient to fuse and then expand the plastisol formulation into a foam. For a PVC plastisol, the temperature range for expanding the foam is generally on the order of about 300° to about 400° F.

In another embodiment, the present invention further provides a process for the manufacture of a non-foamed, film tape product. The non-foamed film tape product is manufactured by providing a continuous liner having a release layer. An adhesive layer is deposited onto the release layer and subsequently dried. After drying the adhesive layer, a barrier film, preferably a vinyl barrier film is disposed on the dried adhesive layer. A liquid plastisol formulation is cast onto the barrier film. Finally, the plastisol formulation is fused to form a thermoplastic film layer on the barrier film.

Barrier films suitable for use in this embodiment of the present invention include, but are not limited to PVC films formulated with plasticizers which are chemically incompatible with the plastisol formulation of the overlying foam or film; and/or flexible and conformable films, preferably PVC films, that have been coated with conventional plasticizer barrier coatings. It is necessary to select a barrier film that has cohesive strength in the construction, and will not delaminate.

A suitable vinyl barrier film formulation thus contains a plasticizer which acts as the barrier to migration of the plasticizer from the foam or thermoplastic layer into the adhesive layer. Without being bound to any particular theory, it is believed that the inhibition of the migration of the plasticizer from the plastisol foam layer into the adhesive layer is accomplished through the use of a vinyl barrier film that contains a plasticizer that is chemically incompatible with the plasticizer contained in the plastisol foam layer. The plasticizers useful in the vinyl film formulation include, but are not limited to the Mesamoll series of plasticizers by Bayer, which are generally more hydrophilic than conventional plasticizers. The most preferred plasticizer is Bayer's Mesamoll-I plasticizer, containing an alkylsulfonic acid ester of phenol.

The preferred vinyl barrier film is therefore cast from a formulation containing one of Bayer's Mesamoll series of plasticizers, and the preferred film with a barrier coating is A 8060 as supplied by VPI Mirrex.

The thickness of the vinyl film that is disposed between the adhesive layer and the plastisol foam layer is generally from about 1 to about 3 mils, more preferably from about 1.5 to about 2.5 mils, and most preferably about 2 mils. The term "mil" refers to a unit of measurement that is equal to one-thousandth of one inch.

The types and characteristics of the liner papers, release compositions, adhesive compositions, and plastisol formulations useful in the plastisol film-adhesive-release liner-backing liner embodiment are the same as for the other above disclosed embodiments of the present invention. The methods of application and operation of the release layer compositions and adhesive compositions are also the same as for the above disclosed embodiments of the present invention, and are widely known in the industry.

We have demonstrated that it is possible to cast a foamable plastisol onto a vinyl barrier film, and still get a good quality foam, comparable to or improved over plastisol foams prepared by casting onto a conventional casting sheet. Further, it was unpredictable that the adhesive would still have adhesive properties once it went through an oven at the high foam expanding temperatures required to fuse and expand PVC plastisols into foam. As in the other embodiments of the present invention, the adhesive, rather than fusing to the silicone compound upon exposure to the high temperature as was expected, releases from the silicone when pulled, but retains sufficient adhering properties for use in the tape product.

The plastisol formulation is applied to the barrier film layer of the barrier film-adhesive-release liner-backing liner construction in a solventless, solution or slurry/dispersion form. Techniques conventional in the industry for applying plastisol formulations to a substrate can be used, such as roll coating, knife over roll coating, and extrusion or slot coating.

A representation of a plastisol foam or film tape 50 having a barrier film layer disposed between the adhesive layer and the plastisol plastisol foam or film layer produced according to the present invention is shown in FIG. 5 (not drawn to scale). The liner backing 51 carries the release layer 52, onto which is disposed the adhesive 53. A barrier film layer 54 is disposed on the dried adhesive, over which is coated the plastisol 55. If the plastisol 55 is to be used as a skin bandage, it is rendered more permeable to air by perforation, such as by passing the foam or film carrying laminate in contact with a roller carrying pins for perforating the foam or film.

EXAMPLES OF THE INVENTION

Polyvinyl chloride (PVC) plastisol formulations prepared according to the examples set forth below were cast on an adhesive coated release liner and tested for acceptability with regard to drape, conformability, and strength characteristics.

Example 1

A plastisol formulation set forth below was prepared and expanded to produce a foam tape, suitable for use in the process of the present invention.

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC dispersion resin 100                                                         Polyester plasticizer 120                                                      Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 1.2                                             Defoamer 0.25                                                                  Aromatic hydrocarbon solvent 16                                                mineral spirits solvent 7                                                      Flesh colored pigments 2.1                                                   ______________________________________                                    

This formulation yielded a soft foam with a tacky texture.

Example 2

For the reduction of solvent in the plastisol, a 30 micron PVC blending resin (VC-260SS) was added to the formulation and the amount of the 1 micron diameter foamable resin (Geon 180X7) was reduced. By the addition of the blending resin, the solvent concentration was reduced from 23 phr to 6 phr without an increase in the final viscosity.

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC dispersion resin 60                                                          PVC blending resin 40                                                          Polyester plasticizer 120                                                      Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 1.2                                             Defoamer 0.25                                                                  Oderless mineral spirits solvent 6                                             Flesh colored pigments 1.1                                                   ______________________________________                                    

The formulation of example 2 yielded a soft foam with nice drape. Physical evaluation of 18 mil foam gave a density of 33 lb./cu.ft., tensile strength of 4.7 lb./in. "down web" or in the machine direction (MD), and elongation of 272% (MD).

Example 3

The plasticizer of Examples 1 and 2 was replaced with a benzyl phthalate plasticizer (Santicizer 278) which is considered a migration resistant high monomeric/low polymeric plasticizer (MW=455). The resulting formulation had the following components:

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC dispersion resin 60                                                          PVC blending resin 40                                                          Benzyl phthalate plasticizer 125                                               Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 1.5                                             Defoamer 0.25                                                                  Odorless mineral spirits solvent 2                                             Flesh colored pigments 1.1                                                   ______________________________________                                    

The formulation of example 3 yielded a stiffer and stronger foam than the formulation of example 2. Physical measurements found the density to be 29 lbs./cu.ft., tensile strength 6.5 lbs./in. (MD), and elongation 240% (MD). Adhesive aging studies up to 4 weeks were investigated on laminated samples with no adhesive failure, and only a 39% drop from initial peel value when aged at 158° F.

Example 4

A phosphate ester plasticizer was added to the benzyl phthalate formulation to soften the foam, and additionally, all solvent was able to be removed. The formulation had the following components:

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC resin            60                                                          PVC blending resin 40                                                          Benzyl phthalate plasticizer 100                                               Phosphate ester plasticizer 15                                                 Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 1.5                                             Defoamer 0.25                                                                  Solvent 0                                                                      Flesh colored pigments 1.1                                                   ______________________________________                                    

The formulation of Example 4 yielded a slightly softer foam than Example 3, with a glossy surface. Physical measurements found the density to be 37 lbs./cu.ft., tensile 5.8 lbs./in. (MD), and elongation 226% (MD). Initial peel studies showed less favorable lamination of the adhesive to the glossy surface of the foam, but aging up to 8 weeks did not display adhesive failure (64% drop from initial peel value when aged at 158° F.).

Example 5

Alternate polymeric plasticizers were also investigated in the plastisol formulation. Polymeric plasticizers resisted plasticizer migration into the acrylic adhesive of the laminate. A polyester adipate plasticizer was therefore substituted in the plastisol formulation. The plastisol had the following formulation:

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC dispersion resin 100                                                         Polyester adipate plasticizer 120                                              Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 1.2                                             Defoamer 0.25                                                                  Odorless mineral spirits solvent 4                                             Flesh colored pigments 1.1                                                   ______________________________________                                    

The formulation of Example 5 produced a very soft foam which tore easily. Density was low, 17 lbs./cu.ft., and a tensile strength of 2.3 lb./in. and elongation of 183% was exhibited.

Example 6

The above formulation using a polyester adipate plasticizer was improved upon by changing the molecular weight of the plasticizer and by adjusting its level in the formulation to produce a stronger foam. The blowing agent level was also reduced to increase the density. The plastisol formulation was as follows:

    ______________________________________                                         Components           phr                                                       ______________________________________                                         PVC dispersion resin 100                                                         Polyester adipate plasticizer 100                                              Activator/stabilizer 3                                                         Azodicarbonamide blowing agent 0.8                                             Defoamer 0.25                                                                  Odorless mineral spirits solvent 3                                             Flesh colored pigments 1.1                                                   ______________________________________                                    

The formulation of Example 6 produced a foam with nice drape. The density was measured as 21 lb./cu.ft. and a tensile strength of 6.2 lb./in. and 285% elongation was exhibited for a 24 mil foam. A 20 mil foam should therefore result in a tensile strength of about 5.5 lb./in. and elongation of about 280%.

Example 7

A polyvinyl chloride film adhesive tape was produced according to the process of the present invention, by omitting the foaming agent and the foam expansion step, using the following formulation.

    ______________________________________                                         Components        phr                                                          ______________________________________                                         PVC dispersion resin                                                                             100                                                            Polyester plasticizer 30                                                       Stabilizer 3                                                                   Defoamer 0.25                                                                  Aromatic solvent 35                                                            Aliphatic solvent 12                                                           Epoxidized Soybean Oil 4                                                     ______________________________________                                    

Polyvinyl chloride (PVC) plastisol formulations prepared according to the examples set forth below were cast onto a vinyl barrier film of a vinyl film/adhesive/release layer/backing liner laminate and tested for acceptability with regard to drape, conformability, strength characteristics, peel adhesion and shrinkage of the expanded plastisol foam layer.

Example 8

Polyvinyl chloride (PVC) plastisol formulations prepared according to the examples set forth above were cast directly onto the vinyl barrier film layer of a vinyl film/adhesive/release layer/backing layer laminate, were foamed, and were tested for acceptability with regard to shrinkage of the expanded plastisol foam layer. The results were compared to plastisol formulations that were cast directly onto the adhesive layer of an adhesive/release layer/backing layer laminate.

The results of Example No. 8 indicates that the plastisol foam layer of the foam/vinyl film/adhesive/release layer/backing layer laminate embodiment of the present invention exhibited a shrinkage of less than about 1%, as compared to a laminate product without a thin vinyl barrier film, which normally has a shrinkage of about 6 to about 8%.

Example 9

Polyvinyl chloride (PVC) plastisol formulations prepared according to the examples set forth above were cast directly onto the vinyl barrier film layer of the vinyl film/adhesive/release layer/backing layer laminate, were foamed, and were tested for acceptability with regard to peel adhesion. The results were compared to plastisol formulations that were cast directly onto the adhesive layer of an adhesive/release layer/backing layer laminate.

The tests results of Example No. 9 indicate that the foam/vinyl film/adhesive/release layer/backing layer laminate embodiment of the present invention has an initial peel adhesion of 1.85 lbs, a peel adhesion of 0.803 lbs after 1 week of aging at 158° F., a peel adhesion of 0.769 lbs. after aging for 2 weeks at 158° F., and a peel adhesion of 1.53 lbs after aging at room temperature for 2 weeks. These results were compared to a laminate product without a thin vinyl barrier film which exhibited an initial peel adhesion of 1.1 lbs, a peel adhesion of 0.6 lbs after 1 week of aging at 158° F., a peel adhesion of 0.5 lbs. after aging for 2 weeks at 158° F., and a peel adhesion of 1 lb. after aging at room temperature for 2 weeks.

The test results of Example Nos. 8 and 9 indicate that the plastisol foam component of the foam/vinyl film/adhesive/release layer/liner laminate embodiment of the present invention experiences only less than about 1% shrinkage in size after aging for 2 weeks at 70° C.

The test results indicate that the addition of the vinyl barrier film results in a foam tape laminate product that demonstrates greater adhesion and a decrease in the shrinkage of the foam layer. In addition, the foam/vinyl film/adhesive/release layer/liner laminate embodiment of the present invention unexpectedly exhibits an increase in the ease of liner release from the product.

We have found that when the plastisol formulation is cast on the vinyl barrier film layer of a vinyl film/adhesive/silicone/liner laminate, a better quality film or foam is achieved compared to one cast on a silicone/liner construction alone, as the adhesive and vinyl barrier layers help to further smooth and densify the surface of substrate. Furthermore, it was unexpectedly discovered that plastisol film or foam tape constructions including the vinyl barrier film requires less adhesive.

The PVC tape manufactured according to the process of the present invention has the following characteristics: Softness, conformability and drape; tensile strength; resistance to tearing; air permeability (transmissibility via perforation); elasticity (percent elongation); processability; cutability (die cutable); and particularly when used for bandages or wound dressings, medical safety (no harmful components); stability over time; resistance to sterilization, steam, and radiation.

The process of the present invention is useful for preparing self-adhesive tape products such as bandages, wound dressings, medical tapes, such as for adhering an electromedical device (e.g., a diagnostic device), mounting tapes, tapes for industrial uses, labels, and the like.

The plastisol foam barrier film/adhesive/release layer/backing liner construction is useful as a tape affixed to electrodes for a human patient. This construction substantially inhibits or minimizes the migration of the plasticizer from the plastisol layer into the adhesive layer, thereby resisting shrinkage of the foam layer, swelling of the electrode and loss of adhesive integrity. This construction is especially useful as a tape for electrodes, because it avoids modification of the electrode signal due to changes in the impedance or resistance of the electrode, and avoids exposing the patient to a risk of electrical shock.

The present invention therefore is demonstrated as providing a process for casting a plastisol derived film or foam tape onto the barrier film layer of a barrier film/adhesive/release layer/backing liner construction. The barrier films acts as a casting sheet, thereby avoiding the use and cost of an additional heavy casting sheet that would otherwise be discarded prior to sizing the width of the tape product.

The continuous plastisol film or foam tape produced by the process of the present invention does not contain sections of spliced film or foam material. According to the prior art, double splices were needed, one in the tape and one in the liner, each time a new roll was put on the apparatus. According to the present invention, only one splice is needed, at the end of the roll of the liner sheet. When the sized tape roll is further processed to replace the liner with the lightweight paper liner, the liner splice goes into the scrap roll.

According to the process of the present invention, a higher quality film or foam tape is achieved by casting the plastisol formulation onto the barrier film layer of a barrier film/adhesive/release layer/backing liner laminate. Improved anchorage of the thermoplastic film or foam layer to the adhesive in the tape product is also obtained through the process of the present invention.

The tape product obtained by the process of the present invention is useful as skin bandages, and therefore the plastisol dispersion used may contain flesh colored pigments, or pigments producing other colors, including but not limited to "designer" colors and fluorescent colors.

Thus, the objects of the invention are accomplished by the present invention, which is not limited to the specific embodiments described above, but which includes variations modifications and equivalent embodiments defined by the following claims. 

We claim:
 1. A process for the manufacture of a plastisol foam tape comprising the steps of:providing a continuous liner having a release layer; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the dried adhesive; casting a foamable liquid plastisol formulation onto the barrier film; and, fusing and expanding the foamable plastisol formulation to form a plastisol foam on the barrier film.
 2. The process as in claim 1 including applying the release layer to the liner prior to the depositing of the adhesive.
 3. The process as in claim 1 wherein the plastisol comprises polyvinyl chloride, plasticizer and a blowing agent.
 4. The process as in claim 3 wherein the plastisol additionally comprises at least one of a polyvinyl chloride blending resin, an activator, a stabilizer, a viscosity depressant, a defoamer, a solvent, a filler and a pigment.
 5. The process as in claim 3 wherein the plastisol formulation is expanded by heating the formulation at about 300° to about 400° F.
 6. The process as in claim 1 further including cutting the tape substantially parallel to its long axis to a selected width.
 7. The process as in claim 1 further including winding the tape onto rolls.
 8. The process as in claim 1 wherein the adhesive comprises an acrylic adhesive.
 9. The process as in claim 1 wherein casting the plastisol formulation comprises one of i) three roll coating, ii) knife over roll coating, and iii) slot coating.
 10. The process as in claim 1 wherein the barrier film is deposited onto the adhesive layer.
 11. The process as in claim 1 wherein the barrier film is laminated onto the adhesive layer.
 12. The process as in claim 1 wherein the thickness of the barrier film is from about 1 mils to about 3 mils.
 13. The process as in claim 1 wherein the barrier film is a vinyl film containing a plasticizer that is chemically incompatible with the plasticizer of the plastisol formulation.
 14. The process as in claim 13 wherein the plasticizer of the vinyl barrier film contains an alkylsulfonic acid ester of phenol.
 15. A foam tape laminate produced by the process of claim
 13. 16. A skin bandage produced by the process of claim
 13. 17. The process as in claim 1 wherein the barrier film is a film having a plasticizer barrier coating.
 18. The process as in claim 1 for the one stage manufacture of a plastisol foam tape laminate, wherein the step of providing a continuous liner having a release layer includes:providing a continuous liner; and forming a release layer along the length of one side of the liner; and further including winding the foam tape laminate onto rolls.
 19. The process of claim 18 wherein the liner comprises a paper liner of about 40 to about 100 pounds weight.
 20. The process of claim 19 wherein the paper liner is clay coated.
 21. The process of claim 18 wherein the release layer comprises a silicone release composition.
 22. The process of claim 21 wherein the release layer comprises a polydimethyl siloxane composition.
 23. The process of claim 1 including depositing the adhesive in a pattern.
 24. The process of claim 1 wherein the adhesive comprises a pressure sensitive adhesive.
 25. The process of claim 1 wherein the adhesive contains a cross-linker.
 26. The process of claim 1 wherein the adhesive comprises a vinyl pyrrolidone polymer and a cross-linker.
 27. The process of claim 1 wherein the adhesive comprises an acrylic polyvinyl ester.
 28. A foam tape laminate produced by the process of claim
 1. 29. A skin bandage produced by the process of claim
 1. 30. A process for the manufacture of a tape plastisol film tape, comprising the steps of:providing a continuous liner having a release layer; depositing an adhesive onto the release layer; drying the adhesive; disposing a barrier film onto the adhesive layer; casting a liquid plastisol formulation onto the barrier film; and, fusing the plastisol formulation to form a thermoplastic film layer on the barrier film.
 31. The process as in claim 30 including applying the release layer to the liner prior to the depositing of the adhesive.
 32. The process as in claim 30 wherein the plastisol comprises polyvinyl chloride, and a plasticizer.
 33. The process as in claim 32 wherein the plastisol additionally comprises at least one of a polyvinyl chloride blending resin, an activator, a stabilizer, a viscosity depressant, a defoamer, a solvent, a filler and a pigment.
 34. The process as in claim 32 wherein the plastisol formulation is fused by heating the formulation at about 300° to about 400° F.
 35. The process as in claim 30 further including cutting the tape substantially parallel to its long axis to a selected width.
 36. The process as in claim 30 further including winding the tape onto rolls.
 37. The process as in claim 30 wherein the adhesive comprises an acrylic adhesive.
 38. The process as in claim 30 wherein the casting the plastisol formulation comprises one of i) three roll coating, ii) knife over roll coating, and iii) slot coating.
 39. The process as in claim 30 wherein the barrier film is deposited onto the adhesive layer.
 40. The process as in claim 30 wherein the barrier film is laminated onto the adhesive layer.
 41. The process as in claim 30 wherein the thickness of the barrier film is from about 1 mils to about 3 mils.
 42. The process as in claim 30 wherein the barrier film is a vinyl film containing a plasticizer that is chemically incompatible with plasticizer contained in the plastisol formulation.
 43. The process as in claim 30 wherein the plasticizer of the vinyl film contains an alkylsulfonic acid ester of phenol.
 44. The process as in claim 30 wherein the barrier film is a film having a plasticizer barrier coating.
 45. The process as in claim 30 for the one stage manufacture of a tape laminate wherein the step of providing a continuous liner having a release layer comprises:providing a continuous liner; and forming a release layer along the length of one side of the liner; and further including winding the resulting tape laminate onto rolls.
 46. The process of claim 45 wherein the liner comprises a paper liner of about 40 to about 100 pounds weight.
 47. The process of claim 46 wherein the paper liner is clay coated.
 48. A film tape laminate produced by the process of claim
 45. 49. A skin bandage produced by the process of claim
 45. 50. The process of claim 45 wherein the release layer comprises a silicone release composition.
 51. The process of claim 50 wherein the release layer comprises a polydimethyl siloxane composition.
 52. The process of claim 30 including depositing the adhesive in a pattern.
 53. The process of claim 30 wherein the adhesive comprises a pressure sensitive adhesive.
 54. The process of claim 30 wherein the adhesive contains a cross-linker.
 55. The process of claim 30 wherein the adhesive comprises a vinyl pyrrolidone polymer and a cross-linker.
 56. The process of claim 30 wherein the adhesive comprises an acrylic polyvinyl ester.
 57. A film tape laminate produced by the process of claim
 30. 58. A skin bandage produced by the process of claim
 30. 59. The process as in claim 1, including depositing the foamable liquid plastisol onto a barrier film-adhesive-release-liner laminate in a stage separate from the depositing of the adhesive.
 60. The process as in claim 30, including depositing the liquid plastisol onto a barrier film-adhesive-release-liner laminate in a stage separate from the depositing of the adhesive. 